Discrete, Repetitive & Process Manufacturing

Hi,
Can discrete, repetitive and process manufacturing operations exist in one SAP client i.e. some products / plants follow discrete manufacturing setup, some products / plants follow repetitive manufacturing setup and some products / plants follow process manufacturing setup? If yes can some one share the control factors for each of the process flows.
Regards,
Arun

Arun,
There is absolutely no problem in having all the PP Process in a single client. Basically the products would be driven based on the material master defination and the associate PP master data created for the products.
Regards,
Prasobh

Similar Messages

Distinguishing features of Discrete and Process Manufacturing?

Hi
I need to know the difference between process and discrete manufacturing environment.
Also, what SAP PP offers to cater both environments?
Plz help.
Edited by: Chris SAP on Aug 5, 2010 5:01 PM

Hi Chrish,
A ) In Pharma the requirement of Key raw material's ingredient will differ based on the active ingredient of other component for key raw material to achieve desired result .
say A + B -
> C   where in A is the key raw material
         100 Kg -
>>> 100 Kg yield where in 100% of A & 50 % B gives 100 % C
         In case A is 90 % and the extra quantity will be consumed from B
In the BOM we have MQC in that formula could be defined for making this balance
B ) difference between Routing and recipe is that In routing we have Operations but in recipe we have Operations & Phases
     and Operations are assigned to the secondary resources
     In recipe we can assign Pi sheet But not in routing .
    recipe have MQC tab but routing dont
   In Routing the Qty is fixed for desired output But in Recipe the input quantity varies based on Active ingredients of the components
I hope you understand pl come back if you have any doubt
Regards,
Jaya vimal
Edited by: jaya vimal on Aug 8, 2010 4:18 PM

Discrete vs Process vs Repetitive?

Can some one explain the difference between Discrete, Process, Repetitive process.
Can we implement all the three process in the same plant??

Hi George,
Find below the documentation from SAP:
REM
You can implement Repetitive Manufacturing if the following is true of your production process:
- You produce the same or similar products over a lengthy period of time.
- You do not manufacture in individually defined lots. Instead, a total quantity is produced over a certain period at a certain rate per part-period.
- Your products always follow the same sequence through the machines and work centers in production.
- Routings tend to be simple and do not vary much.
PP-PI (process)
It is primarily designed for the chemical, pharmaceutical, food and beverage industries as well as the batch-oriented electronics industry. PP-PI supports:
- The integrated planning of production, waste disposal, and transport activities within a plant
- The integration of plants within the company:
- Vertically by means of an information flow, ranging from central business applications down to process control
- Horizontally by the coordination of planning between production plants, recycling and waste disposal facilities, and production laboratories.
Discrete (my views)
Discrete production flow is normally adopted by firms who are manufacturing specialised products eg: custom built machines or where the volumes does not justify to opt for a repetitive kind of setup. Also from finance perspective, when you want to trace the costs at order level & not by period.
Now coming to your qns, whether all three can be implemented in the same plant, well can you let us know what processes are being followed, as to the best of my knowledge, no single plant has all 3 processes working in tandem.
Hope the above was helpful.
Regards,
Vivek

Repetitive or Process Manufacturing?

Dear all,
I've visited a factory that produces "Calcium Carbonate", all they have are production lines with rates and a big mill that feeds its output into these production lines.
I don't know whether they should be using repetitive or process manufacturing?
Can you help and declare why and tell me the difference?
thank you

HI,
As Amol said, it's a high level decision to decide on REM or PE.
Pl. anayse the AS IS BUSINESS PROCESS of the Industry. As you indicated 'Calcium Carbonate' manufacturing is a chemical industry, you may have to go for PI, but you have to maintain Batch Management and cost controlling based on Process orders.
If it's being done on production line and rate routings, the cost controlling will be done based on Product cost collector.
Even it takes time pl. go through the following link, understand the concept and decide. This will help in the long run.
http://help.sap.com/erp2005_ehp_04/helpdata/en/5f/1faba54aee11d189740000e8322d00/frameset.htm
http://help.sap.com/erp2005_ehp_04/helpdata/en/05/603bc6462311d182b50000e829fbfe/frameset.htm
Madhava

Integration with Process Manufacturing

We are looking at upgrading Financials and Process Manufacturing to R11i early next year. Currently we use i2's Rhythm Factory Planner but are interested in the APS developments.
Which APS modules are available for use with OPM? Also where can I get an indicication of the cost per module?

I've got this info from Oracle. Hope this helps. OPM is integrated with APS now.
1. It uses the advanced planning engine and global ATP.
2. Demand Planning integration is in the works.
3. Manufacturing Scheduling is purely a discrete option and not needed for
OPM.
The pricing of APS for OPM is the same as the standard APS and is priced by Cost of Goods Sold. You may get the price details from your local Oracle sales.

Oracle Process Manufacturing Release 11i

Hi there,
Is there a free version of Oracle Process Manufacturing 11i for download? If so what is the site?
Thanks.
Regards,
Leon

Hi All,
Here I talk a step to explain about Discrete, Flow, Process and project manufacturing process.
Discrete:
1. Assemblies are built in specific (discrete) quantities. These jobs or work orders use specific materials and resources.
Say ship building, job shop companies etc are few examples of discrete.
2. Assemblies that are made in groups or batches.
Discrete Manufacturing is a Batch production situation related to most industries like Engineering
It use routings to schedule job production activities and create operation specific material and resource requirements.
Flow:
Flow manufacturing developed to support 'Lean manufacturing'.
Lean manufacturing concepts include:
JIT, pull, value stream mapping, kanban, single piece flow etc.
This module will enable flow manufacturing concerns.
Ex: Car manufacturing
http://forio.com/simulation/oracle/main.htm?page=background&FD_p=1
http://www.psa-peugeot-citroen.com/en/psa_group/visite/index.html
Process:
It is purely for process manufacturing concern
Ex: Chemical industry, pharmateicals etc jus think of chemical laboratory.
Project:
Projects are used to track costs by specifying revenue and billing methods. Each project can have a set of top level tasks, and a hierarchy of subtasks.
As rightly said ETO is example for project manufacturing
To answer your questions
1- A Steel making Company is under Discrete Manufacturing or not?
Depending the concern manufacturing practice only we can say it as discrete or not.
From the above explanation you can able to understand it.
All discrete industry will adopt few lean manufacturing principles to add value in their process.
2- Can we have Discrete & Process in one organization? because some part of my Org like Discrete Manufacturing and other like Process Manufacturing ?
Yes we can have, say for a final product two or more items may come from both discrete and process types.
Hope it is clear and helpful.
Tks
M J

Rework Process of Process Manufacture

HI,
Can you give me some help on setting up a rework process for process manufacture factory?I don't see some function in PI factory, like reference operation set (trigger point)in discret manufacture factory....I don't know how to make it...thanks..

Monst Yang wrote:
HI,pushpalas and all of you:
> thanks very much for your quick reply..
>
> but I need a rework process for PI...I can't find a trigger point function in C201(reciept) to insert a reference operation set...can you tell me how to make it via process order(reciept,resource) instead of production order(router,work center)..
>
>
> thanks..
Hi,
The below mentioned process hold good for Discrete as well as Process manufacturing
Let it be normal routing or master recipe
Open routing and select the operation line item
To assign the Trigger Point function press GOTO MENU and then select Trigger Point Overview
enter trigger point usage and description
Now select trigger point usage line item and click DETAILS menu and select "TRIGGER POINT"
Create Routing Trigger Point Details will appear
Select the check Box="Insert reference operation set"; Sys Status=PCNF; Active=1
now on the top Press the "PARAMETERS BUTTON" assign the group and group counter
come back to the operation overview and save
Regards,
Raj

My iPod Touch attempts to reboot, but shuts-off, creating a repetitive process...?

About a week ago, I was browsing on safari on my 4th generation ipod touch and all of a sudden, the screen froze for a couple of seconds and soon the screen went complete black (you can tell the ipod was still on) and then the apple sign comes up as if my ipod is rebooting itself, but it takes much longer than usual, and then there's a quick flash of whitelight from the screen and immediately shuts off, creating a very repetitive process. About two days later without charging my ipod, so the battery can completely die therefore everything is shut down and soon after, I plug it in to my computer, in hopes that this will increase my chances of my hard earned 64gb ipod touch returns back to normal. In which, did not resolve anything. Itunes won't recognize my ipod, in which will not allow me to restore my ipod back and ever since then, I've had my ipod touch charging from my iphone charger for the past two days, and the process of my ipod rebooting and shuting off is very annoying and frustrating. I'm sadly confident that it's broken, unless I can be informed of some heplful techniques fixing it or informed of some places that can fix mechanical failures like this. Thank You.

First, try a system reset. It cures many ills and it's quick, easy and harmless...
Hold down the on/off switch and the Home button simultaneously until the screen blacks out or you see the Apple logo. Ignore the "Slide to power off" text if it appears. You will not lose any apps, data, music, movies, settings, etc.
If the Reset doesn't work, try a Restore. Note that it's nowhere near as quick as a Reset. Connect via cable to the computer that you use for sync. From iTunes, select the iPad/iPod and then select the Summary tab. Follow directions for Restore and be sure to say "yes" to the backup. You will be warned that all data (apps, music, movies, etc.) will be erased but, as the Restore finishes, you will be asked if you wish the contents of the backup to be copied to the iPad/iPod. Again, say "yes."
Finally, if the Restore doesn't work, let the battery drain completely. Then recharge for at least an hour and Restore again.

Discrete production process after creating sales order with raw materials

Dear all,
I need your support on a specific solution related to discrete production process.
After creating a sales order where the materials are marked as raw materials (ROH), with reference to the sales order the production order is created and the store issues the material for assembly process and is sent for assembly of materials. After assembly of the materials the inventory is added to the sales order stock as same as raw material and after PGI the billing is done for raw material only.
Please let me know the process of raw material to raw material scenario.
Thanks
Seshi

Hi Seshi,
This question seems to be related to ERP rather than to SAP ME. You'd better post it to ERP-related forum. Please use these instructions to find a proper space.
Regards,
Sergiy

New forum for Oracle Process Manufacturing Users

www.opmforums.com
The OPM Forum is a new resource available to end users, consultants, developers and anyone else interested in learning more about making the most out of Oracle Process Manufacturing. OPM Forum brings together experts, proficient users and newbies to promote knowledge sharing, technical exchange and best practices around OPM implementations.
The forum is fully searchable and contains postings around a variety of topics related to OPM. Current topics include data collection, inventory/receiving, order management/shipping, production and quality. The forum is open to the public and registration is free. Once registered, users can:
Post new threads
Reply to other peoples' threads
Edit posts
Receive email notification of replies to posts and threads they specify
Send private messages to other members
Enter events in the forum calendar
Set up a 'buddy-list' to quickly see which friends are currently online
The forum is non-commercial and individual email and/or other personal information is not disclosed.
Check it out for yourself at www.opmforums.com

You can still use this forum. It would better
if we can concentrate all the Text questions on the Oracle Text forum.
null

Special variances in Process Manufacturing

Dear OPM Forum member,
You are in the Oracle Process Manufacturing Community and as a fellow member, I would appreciate your input on leading practices for this case.
A large manufacturer in the Chemicals and Petroleum space has engaged us to collaborate on a footprint to rapidly deploy Oracle Process Manufacturing (OPM) globally.
This Company uses four variance calculations not available in OPM. To illustrate, one of them is Manufacturing Yield Variance. The others are for usage, filling and batch. None of these are available in OPM.
We have identified 2 probable solutions – (1) Calculate these variances in a business intelligence tool or report and then adjust the production formulae for accuracy or (2) extend Subledger Accounting by adding these 4 variances to the existing list.
However, if you solutioned a similar requirement, we would like to know what you did to enhance OPM with these special customer calculations. A writeup, if already available would help us greatly.
Thanks,
Sanjib Manna

Srini
Sorry for my late reply. I was trying to get my arms around these variances and finally have time to update this thread.
Here is the background.
We have a liquid batch for paint intermediate (Master Rex). Intermediate product is yielded to the Filling batch wherein the liquid is filled in drums or containers to produce the final SKU product. There is a separate costing and production formula for the liquid batch and a separate costing and production formula for filling batch. Here are the details on the variances.
1. What is MANUFACTURING YIELD VARIANCE?
1st, M-rex Theoretical Gallons Available is calculated as - Actual Output / Formula weight per gallon.
In the above, Formula weight per gallon is Total Costing Ingredient Quantity / Yield Product Costing Quantity.
2nd, Manufacturing Yield Calculation is calculated as Planned Quantity - Theoretical Gallons Available.
In the above formula, Planned Quantity = Production Formula Planned Quantity.
Manufacturing Yield Variance = Manufacturing Yield Calculation * Product Standard Cost (M-rex).
2. What is USAGE VARIANCE?
= Sum ((Actual Ingredient 1 Quantity - Planned Ingredient 1 Quantity) * Ingredient 1 Standard Cost) + ........)
3. What is FILLING YIELD CALCULATION?
1st, Filling Theoretical Gallons Available is calculated as M-rex Theoretical Gallons Available. In the current domestic system, the filling batch is automatically spawned from M-rex batch once M-rex batch is completed. Additionally, there are automatic system checks to ensure the M-rex quantity in the spawned Filling batch is same as the parent M-rex batch.
2nd, Filling Yield Calculation is calculated as Filling Theoretical Gallons Available - Actual Gallons.
In the above formula, Actual Gallons = Actual Yield * Filling Formula M-rex Quantity.
Filling Yield Variance = Filling Yield Calculation * Product Standard Cost (M-rex).
4. What is METHODS VARIANCE?
I made a 1000 gallon batch, here is the process assuming a standard cost of $1.00 for ingredients A, B and C and product X.
Cost of making 1000 gallons of product X: 1000 Gallons * $1.00 = $1000
Material cost incurred for using Ingredient A: 50 Kgs * $1.00 = $50
Material cost incurred for using Ingredient B: 100 Kgs * $1.00 = $100
Material cost incurred for using Ingredient C: 800 Kgs * $1.00 = $800
Resource charges incurred for producing X: $30
Methods Variance = $1000 – ($50 + $100 + $800 + $30) = $20.
Thanks in advance,
Sanjib

Scenario for Process Manufacturing..

Dear All,
Our client imports goods and then packages them at their site into different packages and boxes. After that those products are dispatched. The client wants to keep an eye on the status of packaging and for that they require a Manufacturing module.
Can Process Manufacturing be implemented for this scenario or Discreet Manufacturing will be a better option?

Hi
Both the way you can choose.
As an OPM Consultant, I prefer to go with Process Manuf. Module.
In your case
1. Your importing your Finished goods and just doing the packing to these Finished goods
2. Now this Packed FG, your are now selling to the Customers
When choose OPM, Here you need to create Formula/Recipe using this you need to perform a Production Batch.
In Formula, keep your Imported Item as Ingredient and Packege Item as (may be box/Cartoon/Sheet....etc) Ingredient and Lables(if required) also as Ingredient and with these Ingredients now you want to make a desired Finished Goods as PRODUCT using Recipe in Production Supervisor Module to complete your Batch.
Now your Packed FG is ready to Ship to Customer.
Hope you understood and implement this.
Regards
Raj
Sierra Atlantic.

What is Process Manufacturing?

Hello All,
Can any tell me what is process manufacturing. As i am a starter, if you could throw some light in detail or brief level, how it works, where it works, for what it is? and What is the better way to start digging in to this module, i mean where is the head and tail?
I am working on Supply chain process- Quote to Cash and procure to pay, is it related to that? or if you have some interesting doc's, if you could forward me and that will be a good start for me [email protected]
Thanks in Advance!
Vinoth

Go through the following links, it should be helpful:
[Process Manufacturing|http://www.oracle.com/applications/manufacturing/Process.html]
[Applications Releases 11i and 12 - Process Manufacturing Manuals|http://http://www.oracle.com/technology/documentation/index.html]
[Note: 417933.1 - Getting Started with R12 - Process Manufacturing FAQ|https://metalink2.oracle.com/metalink/plsql/ml2_documents.showDocument?p_database_id=NOT&p_id=417933.1]

Oracle Process Manufacturing Process Execution Cycle

Hi I am new to OPM and looking for an overview of how OPM works.
I have searched but could not find any specific document.
If anyone is having or knows the process , Please share it.
Thank you in advance..

Hi;
Please see:
Information Center: Oracle Process Manufacturing [ID 1393312.2]
http://docs.oracle.com/cd/E18727_01/doc.121/e13652/T321962T321965.htm
http://docs.oracle.com/cd/A99488_01/acrobat/115gmepeapiug.pdf
http://docs.oracle.com/cd/A85683_01/acrobat/gmetrm.pdf
http://oracleappscommunity.com/oracle/blog/955/oracle-process-manufacturing-process-execution-tables/
Also see:
For r12.1.1:
http://download.oracle.com/docs/cd/B53825_01/current/html/docset.html
For r12:
http://download.oracle.com/docs/cd/B40089_10/current/html/docset.html
For r11:
http://download.oracle.com/docs/cd/A60725_05/r11_doc.htm
Regard
Helios

BR100 Document for Oracle Process Manufacturing (OPM)

Hi,
Can anybody please send me sample BR-100 document for Oracle Process manufacturing for Steel / Coal slag processing industry??
Thanks in advance.
With Regards,
Vishal Gujar
Edited by: 956843 on Dec 14, 2012 12:42 PM

11g is not release yet for SOA Suite. The latest version is 10.1.3.4.
here is some docs to get you started
http://www.oracle.com/technology/products/ias/bpel/htdocs/dev_support.html
cheers
James

Discrete, Repetitive & Process Manufacturing

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